High performance data cable and a UL 910 plenum non-fluorinated jacket high performance data cable

ABSTRACT

We provide a high performance bound lateral shielded twisted pair cables, a high performance data cable containing at least four of the bound lateral shielded twisted pair cables, and a method for preparing the same. The bound lateral shielded twisted pair cables preferably have a 20° C. adjusted standard impedance deviation of 4.5 or less and the high performance data cable contains at least four of the bound lateral shielded twisted pair cables and has a 20° C. adjusted average standard impedance deviation of 4.5 or less. The twisted pair is laterally wrapped with a metal shield tape and a fabric or metal braid or thread at a tension that provides the above. The tension is such that it provides a cross-sectional void area of less than 25% and preferably less than 18% of the lateral shielded twisted pair cable cross-sectional area. The tape is laterally wrapped with an overlap of at least 10% . Preferably, the cables have a rating out to 600 MHz and 1000 MHz. We also provide a UL 910 plenum at least category 5 high-performance data cable that has a non-fluorinated jacket and between the jacket and cable core, a temperature-resistant flame-retardant separator tape.

This application is a 371 of PCT/US00/16344, filed Jun. 14, 2000 andclaims the benefit of provisional application 60/144,998, filed Jul. 22,1999.

FIELD OF THE INVENTION

This invention relates to high performance data cables that successfullyenables transmission in the frequency range of 0.3 MHz to 1200 MHz andespecially in the range of 1.0 to 600 MHz and/or 1.0 to 1000 MHz. Alsoto UL 910 high-performance plenum cables that have a non-fluorinatedjacket. More particularly, the invention relates to high-performancedata cable which are bound-lateral shielded twisted pair cables. Also,this relates more particularly to the at least category 5 plenum UL 910cables having a non-fluorinated jacket and a heat-resistantflame-retardant tape on the inner circumference of the jacket.

BACKGROUND OF THE INVENTION

The current high performance data cables usually utilize as a shield aheavy, stiff, 2 mil aluminum tape with a 1 mil polyester (Mylar)backing. The shield is wrapped around each unshielded twisted pairsubgroup within an application lay length that is equal to the length ofthe cables overall cable lay, typically lays of 4.0 to 6.0 inches. Thetape is about 0.5 inches wide. The application angle of the wrapping isshallow, based on the long overall cable lay (5 inches) and the tape isalmost parallel with the twisted pair laterally axis. A typical cablehas 4 pairs of twisted pair cables with a 40 to 65% tinned copper. braidapplied over the four pairs and a final thermoplastic jacket extrudedover the braided pairs to complete the cable. The shallow applicationangle of the metal shield tape generally creates the problem of allowingthe tape to open up during the cabling operation before a binder orspirally applied drain wire can capture it.

Also, the tape doesn't generally follow the pairs contour under thetape. Tape gaps are created with this process around the unshieldedtwisted pair core that do not provide a sufficiently stable ground planeto meet the industry standard electrical requirements such as CENELEC prEN 50288-4-1.

The known cable structure noted above is mechanically unsound in astatic state, and the electricals are unstable under installationconditions since the single overall braid cannot adequately insure thetape lap doesn't “flower” open when the cable is flexed. This“flowering” increases NEXT, and further erodes impedance/RL performanceas the ground plane is upset. This adds to attenuation non-uniformity.The impedance numbers are even worse under flexing since the conductor'scenter to center, as well as the ground plane, changes. The higher thebandwidth requirement, the worse these issues become.

We know of no cable structure for high performance UL 910 plenum datacables that have a non-fluorinated jacket. A plenum cable that used afluorinated jacket and a temperature-resistant flame-retardant separatortape such as Nomex® (a temperature-resistant flame-retardant nylonmanufactured by DuPont) was used and sold by Belden Wire & Cable Companymore than a year prior to this invention. The Nomex® tape in thosecables kept the fluorinated (FEP) jacket from dripping and producinghigh peak smoke numbers in the UL 910 burn test.

SUMMARY OF THE INVENTION

Our invention uses on each twisted pair cable a lateral wrappedshielding tape that is bound with a fabric or metal binder to meetimpedance/RL, attenuation uniformity, and capacitance unbalance that isrequired.

Our invention eliminates most of the trapped air that is normally foundin shielded twisted pair cables. This is done by utilizing a lateralwrapped shield with preferably a minimum 10% overlap and which has a0.33 to 2.0 mil and preferably a 1 mil metal layer. The lateral wrappedshield is held together by an appropriate binder and preferably by atextile or metal braid or textile helically wrapped thread to providegood shielding with improved impedance control. When desired, a shortfold can be applied along the lateral seam of the shield for improvedEMI/Rfi isolation. The consistent ground plane created along the cableslength allows better capacitance unbalance as well as improvedattenuation uniformity through the reduction of RL reflections andcapacitance unbalance.

Our invention also provides for substantial geometric stability underflexing. The use of a tight lateral shield with at least a 10% overlapand a textile or metal binder, eliminates tape gaps and flowering underflexing. This establishes a very stable level of physical and electricalperformance under adverse use conditions. Our twisted pair cable centerto center distances indicated as (d) in FIG. 3, and conductor to grounddistances, remain much more stable than those of the previous cables.

Our cables are especially beneficial for use as category 7 and higherperformance cables. This is especially true for those cables that welaterally shield and bind and are used out to 600 MHz or 1000 MHz. Thetypical high-performance data cable when made according to ourinvention, has four (4) twisted pair cables with each twisted pair cablemade up of two foam or non-foam insulated (fluorocopolymer orpolyolefin) singles. Each of the twisted pair cables has the uniquetight lateral metal shield tape wrapped around it with the tape and itslateral short fold seam tightly held in place with a tight binder suchas a fabric or metal braid or a helical thread. When a braid is used asthe binder, it is a 40 to 95% braid. When a thread is used, it ispreferably helically wound. The bound-lateral shielded pairs are S-Z'dor planetary together into a bunched or bundled configuration. Thebundled pairs may be bundled by an overall 40 to 95% braid or thread. Afinal thermoplastic jacket (fluorocopolymer or a polyolefin or polyvinylchloride) is extruded over the bundled twisted pair cables.

Generally the metal shield is an aluminum tape or a composite tape suchas a short fold BELDFOIL tape (this is a shield in which metal foil orcoating is applied to one side of a supporting plastic film), or aDUOFOIL tape (this is a shield in which the metallic foil or coating isapplied to both sides of a supporting plastic film) or a free edgeBELDFOIL tape. The overall metal thickness is 0.33 to 2.0 mil aluminumlayer thickness and preferably about a 1.0 mil. Although aluminum isreferred to, any suitable metal normally used for such metal andcomposite metal tapes can be used such as copper, copper alloy, silver,nickel, etc. Each twisted pair is wrapped with the metal facingoutwardly and although the most preferred wrap is about a 25% overlap,the overlap may vary as a practical matter from 10 to 50%. The preferredshield that gives the best attenuation and impedance characteristics arethose tapes that are joined to provide a shorting effect. However, witha suitable overlap, the short fold can be eliminated.

The number of shielded twisted pairs in a high performance data cable isgenerally from 4 to 8 but may be more if desired. The tension of thelaterally wrapped shield and the binder are such that the wrapped shieldand binder eliminate most of the air to provide a standard impedancedeviation for the bound-laterally shielded twisted pair cable and anaverage standard impedance deviation for the high performance data cablewhich has a plurality of laterally shielded twisted pairs. The tensionon the shielding tape and binder are such that there is only a 25% orless and preferably 18% or less void space of the entire cross-sectionalarea of the laterally shielded twisted pair taken along any point in thelength of the cable.

We provide a high performance twisted pair data cable having a shieldlaterally wrapped around an unshielded twisted pair cable and a fabricor metal braid or yarn simultaneously or subsequently wrapped around thelateral shield to bind the shield. The wrapping of the shield andbinder(the braid or thread) is at a tension such that for an individualtwisted pair that may be used on its own, the individual pair has anunfitted impedance that has a nominal or standard impedance deviationfor each bound-laterally shielded twisted pair cable that is rated forup to 600 MHz a standard impedance deviation of 3.5 or less from 1.0 to600 MHz and with no single impedance deviation being greater than 6.0,and for a cable rated for up to 1000 MHz a standard impedance deviation4.5 or less from 1.0-1000 MHz and with no single impedance deviationbeing greater than 6.0. The high-performance data cable which has aplurality of bound-laterally shielded twisted pair cables and is ratedat up to 600 MHz has an average standard impedance deviation for all ofthe plurality of bound-shielded twisted of pairs of 3.5 or less from 1.0to 600 MHz and with no single standard deviation for any of the cablesbeing greater than 6.0. The high-performance data cable which has aplurality of bound-laterally shielded twisted pair cables and is ratedat up to 1000 MHz has an average standard impedance deviation for all ofthe plurality of bound-laterally shielded twisted pairs of and 4.5 orless from 1.0-1000 MHz and with no single standard deviation for any ofthe cables being greater than 6.0. The standard impedance deviation iscalculated around a mean or average impedance of 50 to 200 ohms and withat least 350 frequency measurement taken on a 328 ft. or longer cable.

Also, we provide a high performance data cable that has the ability tobe labeled as a UL910 high performance data plenum cable. This cablepreferably has a non-fluorinated jacket and a temperature-resistantflame-retardant separator tape beneath and in contact with the jacket.

Other advantages of the invention will become more apparent upon readingthe following preferred description taken in conjunction with thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a twisted pair cable used in the presentinvention.

FIG. 2 is a perspective view of a lateral shielded twisted pair cableaccording to the present invention.

FIG. 3 is an enlarged cross-section taken along lines 3—3 of FIG. 2.

FIG. 4A is an enlarged cross-section of a braided lateral shieldedtwisted pair cable according to the present invention.

FIG. 4B is an enlarged cross-section of a thread bound lateral shieldedtwisted pair cable according to the present invention.

FIG. 5 is a cross-section of a cable containing four of the cables ofFIG. 4A.

FIG. 6 is a perspective view of the cable of FIG. 5.

FIG. 7 is a perspective view of a cable containing four of the cables ofFIG. 4B.

FIG. 8 is a perspective view of one of our plenum UL910 high performancedata cables.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates a twisted pair cable 10 having a pair of conductors12 and 13 which are preferably solid copper conductors but can be anyconductor that is suitable for high performance data cables. Each of theconductors 12 and 13 have extruded thereon an appropriate insulation 14and 15 which may be foamed or non-foamed fluorocopolymer or anappropriate polyolefin.

FIG. 2 illustrates the twisted pair of FIG. 1, tightly wrapped with ametal shield 16. The metal shield can be any appropriate shield such asa metal tape or a composite tape with a non-metal base such as apolyester (i.e. MYLAR) having on one or both sides of the non-metal basea metal normally used in cable shields. The metal for the tape and thecomposite tape being aluminum, copper, copper alloy, nickel, silver,etc. The thickness of the overall metal is 0.33 to 2.0 mil andpreferably 1.0 mil. The shield is a metal shield such as, the short foldBELDFOIL type tapes, or the DUOFOIL type tapes which is a tape wheremetal is on both sides of the tape.

The tape 16 is laterally wrapped with sufficient pressure as shown inFIG. 3 so as not to crush the insulation 14 and 15 but to provide asmall void space 17 that is less than 25% of the cross-sectional areashown in FIG. 3. Preferably the void space is less than 18% of thecross-sectional area shown in FIG. 3. The tightly wrapped tape 16conforms to the outer shape of the twisted pair 10 to provide thelaterally shielded twisted pair cable 10A. The tape 16 is wrapped with aslight overlap and with an optional short fold. As noted above, thepreferred thickness of the aluminum or metal is 1 mil. The width of thetape is sufficient to provide a 10% minimum overlap.

As shown in FIGS. 4A and 4B, the shielded twisted pair cable 10A (FIG.3) is tightly held together by a binder 18 or 18′ to provide thebound-shielded cables 10B and 10C. The tension on the tape and binderwrap is sufficiently tight to conform to the contours of the unshieldedtwisted pair 10 to provide a substantially oval cross-sectionconfiguration but is not so tight that it will deform the insulation 14and 15. The lateral wrapping and binding are done at such a tension thatit eliminates substantially most of the air within the bound shieldedtwisted pair cables 10B and 10C. This provides at any point in thelength of the cable, a tight oval cross-section with voids 17. Thistight wrapping provides the standard impedance deviation and the averagestandard impedance deviation noted above.

The insulation is preferably a foamed fluorocopolymer having a thicknessof 0.010-0.060 inches and preferably 0.015 to 0.020 inches. Theindividual conductors 12 and 13 are generally 20 to 30 AWG andpreferably 22 to 24 AWG.

The conductors can be solid or stranded and are preferably solid. Thelay length for all of the four twisted pair cables 10 may be the same ordifferent and right and/or left hand. The lay is preferably 0.3-2.0inches. The overall cable lay is generally 10 to 20 times the cable'saverage core diameter.

The binder 18 is either a fabric (i.e., Aramid) or metal braid which ispreferably a 40-95% braid. The metal is preferably a 45-65% tinnedcopper braid but can be any type metal braid that would be appropriatefor a high performance cable such as category 7 data cable i.e. copper,copper alloy, bronze (a copper alloy which alloying element is otherthan nickel or zinc), silver, etc.

The binder 18′ is a fabric thread (Aramide) that is helically wrapped toprovide a 40-95% binding. We preferably use an Aramid 760 denier threadhaving a ¼ inch helical lay.

Referring to FIG. 5, the bound shielded cable 10B or 10C has a jacket 19extruded thereover to produce the high performance data cable 20 of thepresent invention. The jacket can be any suitable cable jacket materialthat would be suitable for a category 7 cable—a thermoplastic such asflame retardant polyethylene, polyvinyl chloride, fluorocopolymers, etc.

FIG. 6 illustrates a cable 20 having therein four braided-shieldedtwisted pair cables 10B. An optional ground wire 21 is between thecables 10B. The ground wire of course can be located in any suitablelocation such as just under the jacket and/or used to bundle the fourbraided-shielded cables 10B.

FIG. 7 illustrates a cable 25 having therein the four threadbound-shielded twisted pair cables 10C. The four thread bound-shieldedtwisted pair cables 10C are further wrapped or bundled with a metal orfabric braid 22. The braid 22 is generally the same type as that setforth above for braid 18. An optional ground wire 21 is between thecables 10C. As above, the ground wire of course can be located in anysuitable location such as just under the jacket and/or used to bundlethe four thread bound-shielded cables 10C.

FIG. 8 illustrates a cable 30 having a jacket 26, a helically orlaterally wrapped separator tape 27 below the jacket. The separator tape27 surrounds the four twisted pair thread bound-shielded cables 10C andtheir binding braid 22. The jacket 26 is a non-fluorinated jacket suchas polyvinyl chloride. The separator tape 27 is a temperature-resistantflame retardant separator tape such as Nomex®. The construction of thiscable is similar to the cable of FIG. 7 except this cable has theseparator tape 27 and does not have a fluorinated jacket. When desired,the plurality of these non-metal braided or serve shielded twisted paircables can be bundled or wrapped by the ground wire 21. The bundledtwisted pair cables then have the separator tape placed thereover andthe jacket 26 extruded thereover.

As its shown in our following examples 1-7, the high performance braidedlateral shielded twisted pair cables have an unfitted impedance that hasa standard impedance deviation for cables rated up to 600 MHz, of 3.5 orless when taking at least 350 measurements of from 1.0 to 600 MHz andfor cables rated up to 1000 MHz, of 4.5 or less when taking at least 350measurements from 1.0-1000 MHz. The high-performance data cables whichhave a plurality of the braided-shielded twisted pair cables has anaverage standard impedance deviation for all of the plurality ofbraided-shielded twisted pairs of 3.5 or less from 1.0 to 600 MHz and4.5 or less from 1.0-1000 MHz and no single standard impedance deviationis greater than 6.0. The test for all of the Examples was the impedancetests as required by CENELEC and were conducted on 328 ft. lengths ofbound-shielded twisted pair cables wherein the shield was laterallywrapped to provide the twisted pair cables 10A. The lateral shield was aBELDFOIL tape having a 1 mil aluminum thickness. The tape was laterallywrapped with a slight overlap. The lateral tape was bound with a metalbraid. Measurements started at 0.3 MHz and at least three hundred andfifty (350) measurements were taken from about 1 to 600 MHz for Examples1 and 8 and from about 1.0 to 1000 MHz for Examples 2-7. The cableconductors 12 and 13 were 22 AWG solid copper and the insulations 14 and15 were FEP. The measurements were taken at various temperatures andadjusted to 20° C. All of the cables have a void 17 of less than 18% andthe test were taken around the mean impedance close to 100 ohms.

EXAMPLE 1

A 328 ft. length of the above braided-shielded twisted pair cable 10Bwas tested at 23.3° C. The cable impedance was measured over 0.3 to 600MHz and at least 350 measurements were taken between 1.0 and 600 MHz.The braided-shielded twisted pair cable was tested and had a standardimpedance deviation of 1.7714 taken around a mean impedance of 95.2619.

EXAMPLE 2

A 328 ft. length of the above braided-shielded twisted pair cable 10Bwas tested at 23.3° C. The cable impedance was measured over 0.3 to 1000MHz and at least 350 measurements were taken between 1.0 and 1000 MHz.The braided-shielded twisted pair cable was tested and had a standardimpedance deviation of 2.8565 taken around a mean impedance of 94.3178.

EXAMPLE 3

A 328 ft. length of the above high-performance data cable 20 having fourbraided-shielded twisted pair cables 10B was tested at 23.9° C. Theimpedance for each of the four braided-shielded twisted pair cables wasmeasured over 0.3 to 1000 MHz. At least 350 measurements were takenbetween 1.0 and 1000 MHz. The following data was adjusted to 20° C.

The first braided-shielded twisted pair cable had a standard impedancedeviation of 4.2744 taken around a mean impedance of 100.5321.

The second braided-shielded twisted pair cable had a standard impedancedeviation of 5.1630 taken around a mean impedance of 101.4416.

The third braided-shielded twisted pair cable had a standard impedancedeviation of 4.0469 taken around a mean impedance of 101.4583.

The fourth braided-shielded twisted pair cable had a standard impedancedeviation of 4.3360 taken around a mean impedance of 100.7506.

The high-performance cable 20 of this example had an average standardimpedance deviation of 4.4551 ((4.2744+5.1630+4.0469+4.3360)/4).

EXAMPLE 4

A 328 ft. length of the above high-performance data cable 20 having fourbraided-shielded twisted pair cables 10B was tested at 23.9° C. Theimpedance for each of the four braided-shielded twisted pair cables wasmeasured over 0.3 to 1000 MHz. At least 350 measurements were takenbetween 1.0 and 1000 MHz. The following data was adjusted to 20° C.

The first braided-shielded twisted pair cable had a standard impedancedeviation of 4.0430 taken around a mean impedance of 101.1783.

The second braided-shielded twisted pair cable had a standard impedancedeviation of 4.0027 taken around a mean impedance of 101.3086.

The third braided-shielded twisted pair cable had a standard impedancedeviation of 3.6038 taken around a mean impedance of 101.7716.

The fourth braided-shielded twisted pair cable had a standard impedancedeviation of 4.0092 taken around a mean impedance of 101.3598.

The high-performance cable 20 of this example had an average standardimpedance deviation of 3.9147 ((4.0430+4.0027+3.6038+4.0092)/4).

EXAMPLE 5

A 328 ft. length of the above high-performance data cable 20 having fourbraided-shielded twisted pair cables 10B was tested at 23.9° C. Theimpedance for each of the four braided-shielded twisted pair cables wasmeasured over 0.3 to 1000 MHz. At least 350 measurements were takenbetween 1.0 and 1000 MHz. The following data was adjusted to 20° C.

The first braided-shielded twisted pair cable had a standard impedancedeviation of 3.2469 taken around a mean impedance of 199.2035.

The second braided-shielded twisted pair cable had a standard impedancedeviation of 4.2070 taken around a mean impedance of 100.9596.

The third braided-shielded twisted pair cable had a standard impedancedeviation of 3.4690 taken around a mean impedance of 102.8214.

The fourth braided-shielded twisted pair cable had a standard impedancedeviation of 3.8990 taken around a mean impedance of 101.2338.

The high-performance cable 20 of this example had an average standardimpedance deviation of 3.7055 ((3.2469+4.2070+3.4690+3.8990)/4).

EXAMPLE 6

A 328 ft. length of the above high-performance data cable 20 having fourbraided-shielded twisted pair cables 10B was tested at 24.2° C. Theimpedance for each of the four braided-shielded twisted pair cables wasmeasured over 0.3 to 1000 MHz. At least 350 measurements were takenbetween 1.0 and 1000 MHz. The following data was adjusted to 20° C.

The first braided-shielded twisted pair cable had a standard impedancedeviation of 4.0488 taken around a mean impedance of 101.4423.

The second braided-shielded twisted pair cable had a standard impedancedeviation of 4.2081 taken around a mean impedance of 100.9498.

The third braided-shielded twisted pair cable had a standard impedancedeviation of 4.5567 taken around a mean impedance of 102.0121.

The fourth braided-shielded twisted pair cable had a standard impedancedeviation of 3.6408 taken around a mean impedance of 102.9531.

The high-performance cable 20 of this example had an average standardimpedance deviation of 4.1136 ((4.0488+4.2081+4.5567+3.6408)/4).

EXAMPLE 7

A 328 ft. length of the above high-performance data cable 20 having fourbraided-shielded twisted pair cables 10B was tested at 24.2° C. Theimpedance for each of the four braided-shielded twisted pair cables wasmeasured over 0.3 to 1000 MHz. At least 350 measurements were takenbetween 1.0 and 1000 MHz. The following data was adjusted to 20° C.

The first braided-shielded twisted pair cable had a standard impedancedeviation of 3.6939 taken around a mean impedance of 102.0776.

The second braided-shielded twisted pair cable had a standard impedancedeviation of 3.8658 taken around a mean impedance of 100.4614.

The third braided-shielded twisted pair cable had a standard impedancedeviation of 3.5208 taken around a mean impedance of 99.7808.

The fourth braided-shielded twisted pair cable had a standard impedancedeviation of 3.9835 taken around a mean impedance of 100.0594.

The high-performance cable 20 of this example had an average standardimpedance deviation of 3.7660 ((3.6939+3.8658+3.5208+3.9835)/4).

EXAMPLE 8

A 328 ft. length of the above high-performance data cable 20 having fourbraided-shielded twisted pair cables 10B was tested at 24.4° C. Theimpedance for each of the four braided-shielded twisted pair cables wasmeasured over 0.3 to 600 MHz. At least 350 measurements were takenbetween 1.0 and 600 MHz. The following data was adjusted to 20° C.

The first braided-shielded twisted pair cable had a standard impedancedeviation of 3.5621 taken around a mean impedance of 102.2971.

The second braided-shielded twisted pair cable had a standard impedancedeviation of 3.9185 taken around a mean impedance of 103.9484.

The third braided-shielded twisted pair cable had a standard impedancedeviation of 2.6943 taken around a mean impedance of 103.2519.

The fourth braided-shielded twisted pair cable had a standard impedancedeviation of 2.5206 taken around a mean impedance of 102.9625.

The high-performance cable 20 of this example had an average standardimpedance deviation of 3.1739 ((3.5621+3.9185+2.6943+2.5206)/4).

EXAMPLE 9

Two cables of FIG. 8 were UL 910 tested. Each cable had four twistedpair thread bound-shielded cables 10C. Each of the cables shields 16 wasa 2 mils aluminum/0.5 mills polyester tape having a 0.625 inch width.Each of the shields 16 were bound with an Aramid 760 thread. The fourthread bound-shielded cables were wrapped with a 40% tinned copperbraid. The four braid bundled cables were wrapped with a 2 mils Nomexseparator tape having a 1.250 inch width. Over the separated tape was anextruded polyvinyl chloride jacket. Both cables passed the UL 910 plenumtest. During the UL 910 plenum test, the first cable registered a flameof 1.5 ft., a 0.32 Peak and a 0.09 Avg P/F. The second cable registereda flame of 1.5 ft., a 0.29 Peak and a 0.09 Avg P/F. Both cables would berated as category 7 cables with a rating of up to 1000 MHz.

Although our invention for the UL 910 plenum at least category 5high-performance data cable was UL 910 tested on the cable of FIG. 8which is a category 7 cable, it is understood that our invention is tobe considered as not being limited to this specific construction of thecable but is directed to any category 5 or higher cable utilizing anon-fluorinated jacket such as a polyvinyl chloride jacket and betweenthe jacket and cable core there is a temperature-resistantflame-retardant separator tape. For instance we provide a UL 910 plenumhigh-performance data cable having a rating of up to 600 MHz that hasthe structure disclosed in our co-pending application, which are tightlywrapped helical shielded twisted pair cables, and utilizing in thatcable a non-fluorinated jacket such as a polyvinyl chloride jacket andbetween the jacket and cable core, a temperature-resistantflame-retardant separator tape. Our UL 910 plenum at least category 5high-performance data cable is not limited to the cables just mentionedabove but is for UL 910 plenum at least category 5 high-performance datacable that has a non-fluorinated jacket and between the jacket and cablecore, a temperature-resistant flame-retardant separator tape.

It will, of course, be appreciated that the embodiments which have justbeen described have been given by way of illustration, and the inventionis not limited to the precise embodiments described herein. Variouschanges and modifications may be effected by one skilled in the art atwithout departing from the scope or spirit of the invention as definedin the appended claims.

We claim:
 1. An individual bound lateral shielded twisted pair datacable comprising: an insulated twisted pair cable, a shielding tapeselected from the group consisting of a metal tape, a first compositetape having a non-metal base and a layer of metal on one side of saidbase, and a second composite tape having a non-metal base and a layer ofmetal on both sides of said base; said shielding tape being laterallywrapped with at least a 10% overlap around said individual twisted paircable; a fabric or metal binder being wrapped around said shielding tapeto provide a bound lateral shielded twisted pair cable; said shieldingtape having a metal thickness of 0.33 to 2.00 mils; said shielding tapeand binder being wrapped around said twisted pair at a tension toeliminate a substantial amount of the air and to leave a cross-sectionalvoid area of less than 25% of the cross-sectional area of the shieldedtwisted pair cable to provide said bound lateral shielded twisted pairdata cable; and to provide said bound lateral shielded twisted pair datacable with an adjusted to 20° C. standard impedance deviation of 4.5 orless when said standard deviation is calculated around a mean or averageimpedance of 50 to 200 ohms.
 2. The cable of claim 1 wherein, said cablehas a rating out to 1000 MHz., and said standard deviation is measuredon a 328 ft. or longer cable with at least 350 frequency measurementstaken from 1.0 to 1000 MHz and calculated around a mean or averageimpedance of 90 to 110 ohms.
 3. The cable of claim 2 wherein saidcross-sectional void area is less than 18%, and said shielding tape hasa metal thickness of 0.75 to 1.25 mils.
 4. The cable of claim 1 wherein,said cable has a rating out to 600 MHz, and said impedance deviation ismeasured on a 328 ft. or longer cable with at least 350 frequencymeasurements taken from 1.0 to 600 MHz and said standard impedancedeviation is 3.5 or less and calculated around a mean or averageimpedance of 90 to 110 ohms.
 5. The data cable of claim 3 wherein saidcross-sectional void area is less than 18%, and said shielding tape hasa metal thickness of 0.75 to 1.25 mils.
 6. The cable of claim 1 furthercomprising at least four of said individually bound lateral shieldedtwisted pair cables, a jacket surrounding said at least four boundlateral shielded twisted pair cables to provide a high performance datacable; and said high performance data cable having an adjusted to 20° C.average standard impedance deviation of 4.5 or less when taken on a 328ft. or longer said average standard impedance deviation is the averageof the standard impedance deviation measured on each of said at leastfour bound lateral shielded twisted pair cables, the standard impedancedeviation is measured on each of said at least four bound lateralshielded twisted pair cables with at least 350 frequency measurementstaken and calculated around a mean or average impedance of 50 to 200ohms.
 7. The cable of claim 6 wherein said high performance data cableis rated at least out to 600 MHz, each of said at least four boundlateral shielded twisted pair cables has a cross-sectional void area ofless than 18%, said high performance data cable has an adjusted to 20°C. average standard impedance deviation of 3.5 or less when taken on a328 ft. or longer high performance data cable, the standard impedancedeviation is measured on each of said at least four bound-shieldedtwisted pair cables with at least 350 frequency measurements from 1.0 to600 MHz and calculated around a mean or average impedance of 90 to 110ohms, and no single standard impedance deviation is greater than 6 fromsaid mean or average impedance.
 8. The cable of claim 6 wherein, highperformance data cable is rated at least out to 1000 MHz, each of saidat least four bound lateral shielded twisted pair cables has across-sectional void area of less than 18%, said high performance datacable has an adjusted to 20° C. average standard impedance deviation of4.5 or less when taken on a 328 ft. or longer high performance datacable, the standard impedance deviation is measured on each of said atleast four bound-shielded twisted pair cables with at least 350frequency measurements from 1.0 to 1000 MHz and calculated around a meanor average impedance of 90 to 110 ohms, and no single standard impedancedeviation is greater than 6 from said mean or average impedance.
 9. Thecable of claim 6 wherein, a temperature-resistant flame-retardantseparator tape surrounds said at least four bound lateral shieldedtwisted pair cables and is between said jacket and a cable core, andsaid jacket is a non-fluorinated polyolefin.
 10. The cable of claim 6wherein said high performance data cable is rated at least out to 600MHz, each of said at least four bound lateral shielded twisted paircables has a cross-sectional void area of less than 18%, said highperformance data cable has an adjusted to 20° C. average standardimpedance deviation of 3.5 or less when taken on a 328 ft. or longerhigh performance data cable, the standard impedance deviation ismeasured on each of said at least four bound-shielded twisted paircables with at least 350 frequency measurements from 1.0 to 600 MHz andcalculated around a mean or average impedance of 90 to 110 ohms, and nosingle standard impedance deviation is greater than 6 from said mean oraverage impedance. a temperature-resistant flame-retardant separatortape surrounds said at least four bound lateral shielded twisted paircables and is between said jacket and a cable core, and said jacket is anon-fluorinated polyolefin.
 11. The cable of claim 6 wherein, said highperformance data cable is at least rated out to 1000 MHz, each of saidat least four bound lateral shielded twisted pair cables has across-sectional void area of less than 18%, said high performance datacable has an adjusted to 20° C. average standard impedance deviation of4.5 or less when taken on a 328 ft. or longer high performance datacable, the standard impedance deviation is measured on each of said atleast four bound lateral shielded twisted pair cables with at least 350frequency measurements from 1.0 to 1000 MHz and calculated around a meanor average impedance of 90 to 110 ohms, and no single standard impedancedeviation is greater than 6 from said mean or average impedance. atemperature-resistant flame-retardant separator tape surrounds said atleast four bound lateral shielded twisted pair cables and is betweensaid jacket and a cable core, and said jacket is a non-fluorinatedpolyolefin.
 12. A UL 910 plenum high performance data cable comprising acable core containing at least four twisted pair cables, each of thesaid twisted pair cables being laterally shielded and bound to provideat least four bound lateral shielded twisted pair cables, atemperature-resistant flame retardant separator tape surrounds the atleast four bound lateral shielded twisted pair cables, said separatortape being between said jacket and a cable core, and said jacket is anon-fluorinated polyolefin wherein said separator tape is wrapped aroundthe twisted pair at a tension to eliminate a substantial amount of theair and to leave a cross sectional void area of less than 25% of thecross sectional area of the shielded twisted pair cables to provide thebound lateral shielded twisted pair cable and to provide the boundlateral shielded twisted pair cable with an adjusted 20° C. standardimpedance deviation of 4.5 or less when said standard deviation iscalculated around a mean or average impedance of 50 to 200 ohms.
 13. Thecable of claim 12 wherein said cable is at least rated out to at least600 MHz, and said high performance data cable has an adjusted to 20° C.average standard impedance deviation of 3.5 or less when taken on a 328ft. or longer high performance data cable, the standard impedancedeviation is measured on each of said at least four pairs of cables withat least 350 frequency measurements from 1.0 to 600 MHz and calculatedaround a mean or average impedance of 90 to 110 ohms, and no singlestandard impedance deviation is greater than 6 from said mean or averageimpedance.
 14. The cable of claim 12 wherein said cable is rated out toat least 1000 MHz, said high performance data cable has an adjusted to20° C. average standard impedance deviation of 4.5 or less when taken ona 328 ft. or longer high performance data cable, the standard impedancedeviation is measured on each of said at least four pairs of cables withat least 350 frequency measurements from 1.0 to 1000 MHz and calculatedaround a mean or average impedance of 90 to 110 ohms, and no singlestandard impedance deviation is greater than 6 from said mean or averageimpedance.
 15. A method of preparing an individual bound lateral twistedpair data cable comprising: providing a twisted pair cable having aninsulation selected from the group consisting of foamed or non-foamedfluorocopolymer and polyolefin; laterally wrapping said twisted paircable with a metal shielding tape to provide a lateral shielded twistedpair cable with at least a 10% overlap of said shielding tape and saidshielding tape having a metal thickness of 0.33 to 2.00 mils, and saidshielding tape being selected from the group consisting of a metal tape,a first composite tape having a non-metal base and a layer of metal onone side of said base, and a second composite tape having a non-metalbase and a layer of metal on both sides of said base; wrapping saidlateral shielded twisted pair cable with a fabric or metal binder toprovide a bound lateral shielded twisted pair cable; and wrapping thelateral metal shield and binder at a tension to provide said boundlateral shielded twisted pair cable with an adjusted to 20° C. standardimpedance deviation of 4.5 or less when said standard impedancedeviation is measured on a 328 ft. or longer cable with at least 350frequency measurements being taken and the standard impedance beingcalculated around a mean or average impedance of 50 to 200 ohms.
 16. Themethod of claim 15 wherein said shielding tape has a metal thickness of0.75 to 1.25 mils, wrapping and binding the twisted pair cables so thatsaid cross-sectional void area is less than 18%, and said cable having arating out to 600 MHz, said at least 350 frequency measurements aretaken from 1.0 to 600 MHz, and said standard deviation is 3.5 or lessand calculated around a mean or average impedance of 90 to 110 ohms andno single deviation is greater than 6 from said mean or averageimpedance.
 17. The method of claim 15 wherein said shielding tape has ametal thickness of 0.75 to 1.25 mils, wrapping and binding the twistedpair cables so that said cross-sectional void area is less than 18%, andsaid cable having a rating out to 1000 MHz, said at least 350 frequencymeasurements taken from 1.0 to 1000 MHz, and said standard deviation is4.5 or less and calculated around a mean or average impedance of 90 to110 ohms and no single deviation is greater than 6 from said mean oraverage impedance.
 18. The method of claim 15 further comprisingbundling at least four of said bound lateral shielded twisted paircables, extruding a jacket over the at least four individually boundlateral shielded twisted pair bundled cables to provide a highperformance data cable, and selecting said at least four individuallybound lateral shielded twisted pair cables to provide said highperformance data cable with a rating out to 600 MHz, an average standardimpedance deviation of 3.5 or less when taken on a 328 ft. or longerhigh performance data cable wherein a standard impedance deviation ismeasured on each of said at least four bound lateral shielded twistedpair cables with at least 350 frequency measurements and taken andcalculated around a mean or average impedance of 90 to 110 ohms, andsaid average standard impedance deviation is the average of saidstandard impedance deviation measured on all of said at least four boundlateral shielded twisted pair cables.
 19. The method of claim 18 furthercomprising prior to extruding the jacket, wrapping a heat-resistantflame-retardant separator tape around at least four bound lateralshielded twisted pair cables such that the temperature-resistantflame-retardant separator tape is between said jacket and a cable core,and said jacket is a non-fluorinated polyolefin.
 20. The method of claim15 further comprising bundling at least four of said individually boundlateral shielded twisted pair cables, extruding a jacket over the atleast four bound lateral shielded twisted pair bundled cables to providea high performance data cable, and selecting said at least four boundlateral shielded twisted pair cables to provide said high performancedata cable with a rating out to 1000 MHz, an average standard impedancedeviation of 4.5 or less taken when on a 328 ft. or longer highperformance data cable wherein a standard impedance deviation ismeasured on each of said at least four bound lateral shielded twistedpair cables with at least 350 frequency measurements and taken andcalculated around a mean or average impedance of 90 to 110 ohms, andsaid average standard impedance deviation is the average of saidstandard impedance deviation measured on all of said at least four boundlateral shielded twisted pair cables.
 21. The method of claim 20 furthercomprising prior to extruding the jacket, wrapping said heat-resistantflame-retardant tape around said at least four bound lateral shieldedtwisted pair cables such that the temperature-resistant flame-retardantseparator tape surrounds is between said jacket and a cable core, andsaid jacket is a non-fluorinated polyolefin.